MES: Manufacturing Execution System & Intelligence

CORE ARCHITECTURE

Deterministic Shop Floor Execution & OEE Intelligence

Four interconnected modules engineered to eliminate paper traveler sheets, localize micro-stoppages, and automate error-proofing across your entire plant.

01 / TELEMETRY

Real-Time OEE & Downtime Analytics

Continuous mathematical breakdown of Availability, Performance, and Quality. Automatically detects machine micro-stoppages, operator waiting states, and speed degradation without manual logbooks.

✓ Automated Downtime Reason Tree

✓ Takt Time vs Planned Pacing

✓ Shift & Line OEE Heatmaps

02 / EXECUTION

Connected Workstation Poka-Yoke

Digitize assembly lines with rugged touchscreen operator guidance. Synchronizes live CAD blueprints, step-by-step assembly validation, torque tool interlocks, and Zebra serialized label printing.

✓ Dynamic SKU SOP Touchscreens

✓ Barcode & Zebra Label Trigger

✓ Sub-Assembly Gate Interlocks

03 / AUTOMATION

Direct PLC & Fieldbus Ingestion

Connect directly to Siemens, Rockwell Allen-Bradley, Mitsubishi, and Omron PLCs via OPC-UA, Profinet, and Modbus TCP. Samples hardware I/O deterministically under 15ms.

✓ Native Multi-Protocol Gateway

✓ Air-Gapped Edge Server Ingest

✓ Sub-15ms Machine Trip Controls

04 / INTEGRATION

Enterprise ERP & SAP Sync

Two-way closed-loop integration with SAP S/4HANA, Siemens Opcenter, Oracle, and Microsoft Dynamics. Real-time work order dispatching, material consumption, and serialized batch genealogy.

✓ Bi-Directional ERP Dispatch

✓ 100% Serialized Unit Genealogy

✓ Paperless Audit Compliance

YAFE MES connected assembly workstation deployment at Mahindra manufacturing plant

Mahindra Assembly Plant • Live MES Station

SHOP FLOOR WORKSTATION EXECUTION

Connected Operator Terminals & Automated Poka-Yoke

In high-precision assembly lines like automotive chassis and powertrain manufacturing, human error leads to costly downstream rework. YAFE MES equips each workstation with ruggedized touchscreens, visual work instructions, and integrated barcode labeling.

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Interactive Touchscreen SOPs: Operators are guided through visual assembly steps with dynamic SKU schematics, preventing skipped fasteners and wrong part orientations.

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Integrated Zebra Label Printing: Serialized unit barcodes and inspection certification labels print automatically only after all station checkpoints are validated.

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Pneumatic Line Interlocking (Poka-Yoke): If an assembly step is incomplete or torque limits are out of spec, the conveyor interlock holds the unit at the station.

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Instant Operator Andon Paging: Station supervisors and maintenance teams receive real-time alerts the moment takt pacing slips behind schedule.

Request an Assembly PoC →

HARDWARE-LEVEL MACHINE TELEMETRY

Direct Machine PLC Control & Edge Server Telemetry

True Manufacturing Execution requires direct, deterministic communication with machine control cabinets. The on-premises YAFE Server connects directly to plant PLCs (Siemens S7, Rockwell ControlLogix, Mitsubishi) to capture hardware cycles at microsecond granularity.

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Multi-Protocol Fieldbus Ingestion: Native support for OPC-UA, Profinet, EtherNet/IP, Modbus TCP, and digital optoisolated relays without modifying machine ladder logic.

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Air-Gapped On-Premises Security: The YAFE Server operates 100% locally within the plant OT network, ensuring zero cloud dependency and strict data sovereignty.

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Automated Micro-Stoppage Categorization: Distinguish between mechanical jams, sensor trips, operator wait times, and raw material feed shortages automatically.

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Sub-15ms Bidirectional Interlocks: Signal safety relays and pneumatic diverters deterministically to stop defective assemblies before expensive downstream processes.

View Technical Specifications →

YAFE Server rack and industrial machine PLC control panel interfacing

PLC Cabinet & YAFE Edge Server • Sub-15ms Ingest

PRODUCTION MODULES IN ACTION

Explore the YAFE MES Modules

Click through the core operating modules below to see how YAFE connects shop floor execution, PLC signals, and top-floor ERP.

Direct PLC Control Panel and YAFE Server

MODULE 01 • WORKSTATION EXECUTION

Connected Assembly & Poka-Yoke Guidance

Provide operators with interactive digital work instructions, automated torque tracking, and synchronized Zebra barcode printing. Pneumatic interlocks prevent defective assemblies from advancing.

✓ SKU-specific CAD blueprints and animated assembly checkpoints

✓ Sub-second pneumatic interlocks prevent defective part advance

✓ Direct Zebra label generation for certified finished goods

PROVEN PRODUCTION METRICS

Quantified ROI Across Enterprise Manufacturing

Real deployment statistics from automotive, heavy engineering, and process manufacturing plants powered by YAFE MES.

Mahindra & Mahindra • Automotive

Assembly Line MES

62% → 84% OEE

Digitized assembly workstations, automated Poka-Yoke interlocks, and slashed rework by 34% across high-volume automotive production.

Saint-Gobain • Process Plants

Recipe & Batch MES

99.8% Compliance

Automated formulation dispatching and serialized raw material batch genealogy with zero escaped recipe variance.

Wheels India • Component Tier-1

OEE & Downtime Telemetry

-40% Micro-Stops

Direct machine PLC interfacing automatically classified root causes for micro-stoppages, boosting weekly shift availability by 18%.

Apollo Tyres • Serialization

Unit Genealogy Traceability

100% Traceability

Every cured and inspected tire is tracked with timestamp, curing mold telemetry, and cryptographically verified DOT code compliance.

Autonomous MES & Manufacturing Intelligence Platform